π H-4709
BIG JOE® ELECTRIC
PALLET TRUCK
1-800-295-5510
uline.com
TROUBLESHOOTING
MALFUNCTION
PROBABLE CAUSE
CORRECTIVE ACTION
TRUCK AND HYDRAULIC
SYSTEM WILL NOT OPERATE
a. Fuse blown.
Check fuse and replace if necessary.
b. Battery dead or disconnected.
Check battery connections and
battery voltage.
c. Key switch defective.
Bypass key switch to determine if it is
malfunctioning.
d. Defective wiring.
Check for open circuit. Repair as
required.
a. A loose connection may be the
cause of malfunction.
Tighten all loose connections before
further troubleshooting.
b. Defective deadman switch.
Check and replace switch if
defective.
c. Defective controller.
Check for proper operation and
replace if defective.
d. Defective potentiometer.
Check and replace potentiometer if
defective.
Truck travels forward but not
in reverse.
Defective potentiometer.
Check and replace potentiometer if
defective.
Truck travels reverse but not
forward.
Defective potentiometer.
Check and replace potentiometer if
defective.
Truck travels forward and in
reverse at lower speeds; will
not travel at high speed.
Defective potentiometer.
Check and replace potentiometer if
defective.
Truck will not travel, nor will lift
system operate.
TRUCK DOES NOT OPERATE
FORWARD OR REVERSE
Truck does not travel forward
or reverse. All other functions
operate normally.
PAGE 1 OF 3
0115 TH-4709
π H-4709
BIG JOE® ELECTRIC
PALLET TRUCK
MALFUNCTION
1-800-295-5510
uline.com
PROBABLE CAUSE
CORRECTIVE ACTION
TROUBLE WITH BRAKING
a. Defective deadman switch.
Check deadman switch for continuity.
If none found when the control arm is
in the brake position, replace switch.
b. Defective electric brake.
Replace brake.
a. Brake temperature above 281° F.
Allow to cool.
b. Open brake circuitry or wiring.
Make voltage checks.
Brake drags.
Defective electric brake.
Replace brake.
Brake grabs.
Defective electric brake.
Replace brake.
Abnormal noise and chatter
when brake is applied.
Defective electric brake.
Replace brake.
Oil leaks from the top of the
lift cylinder.
Defective packing in lift cylinder.
Repair lift cylinder.
Squealing sounds when lifting
forks.
a. Oil level too low.
Add oil to reservoir.
b. Lift linkage binding.
Apply grease.
Forks do not lift to top.
Oil level too low. Brake is applied.
Add oil to reservoir.
Weak, slow or uneven action
of hydraulic system.
a. Defective pump or relief valve.
Check pressure. Adjust as needed.
b. Worn lift cylinder.
Replace cylinder.
c. Load larger than capacity.
Refer to I.D. plate for capacity.
d. Defective lift motor solenoid.
Replace solenoid on electrical panel.
e. Battery charge low.
Charge battery.
a. Battery is dead or disconnected.
Check and recharge if required.
b. Defective wiring.
Check and repair as required.
c. Defect in electrical system for
operating pump motor.
Check lift switch in control head
and the solenoid.
Defect in hydraulic system.
Check the oil level in the reservoir and
the oil lines to the lift cylinder and
repair as required. If normal, check
the hydraulic pump and relief valve.
Repair or adjust.
Truck does not slow with
brake, or brake does not
engage.
Brake will not release.
TROUBLE WITH LIFTING OR
LOWERING
Forks do not lift, pump motor
does not run.
Forks do not lift, motor runs.
PAGE 2 OF 3
0115 TH-4709
π H-4709
BIG JOE® ELECTRIC
PALLET TRUCK
MALFUNCTION
1-800-295-5510
uline.com
PROBABLE CAUSE
CORRECTIVE ACTION
TROUBLE WITH LIFTING OR
LOWERING - CONTINUED
Forks lift, but will not go down.
Defect in hydraulic system.
Check lowering control switch in
control head and lowering solenoid
on valve assembly. Replace as
required.
Load will not hold.
a. Oil bypassing internally in control
valve.
Replace valve assembly.
b. Worn lift cylinder or packing.
Repack cylinder.
a. Oil level too low.
Add oil to reservoir.
b. Load larger than capacity.
Refer to I.D. plate for capacity.
c. Batteries need charging.
Charge batteries.
Leak in hydraulic system, lift cylinder or
lowering valve.
Check for leaking fitting in hydraulic
line and repair as required. Repack
lift cylinder or replace valve
assembly.
Steering arm does not return
to the upright position.
a. Weak return spring.
Replace spring.
b. Binding.
Check and free the binding item.
Verify that the cable has not been
damaged. Repair or replace as
needed.
Truck moves forward when
arm is pulled down.
a. Belly-button switch defective.
Check for short and repair or replace
as necessary.
b. Short in control head.
Check wiring and repair as required.
Steering arm jerks excessively
when starting or stopping the
truck.
Drive wheel worn.
Replace drive wheel if worn to within
3/4" of hub.
Drive motor is jerky.
Motor internally damaged or worn.
Replace motor.
Forks do not lift to top. Pump
motor runs.
Forks creep downward
under load when in a raised
position.
MISCELLANEOUS
PAGE 3 OF 3 π CHICAGO • ATLANTA • DALLAS • LOS ANGELES • MINNEAPOLIS • NYC/PHILA • SEATTLE • MEXICO • CANADA
0115 TH-4709